Egg carton

ABSTRACT

An egg carton having a latching arrangement which includes inwardly projecting lugs on a front panel of the carton top cover which extend into corresponding holes on a latching flap attached to the carton tray. Reinforcing ribs extend across the carton top joining its front and rear panels to prevent spreading of the front panel. Depressions also are formed in the front panel of the carton top into which corresponding stacking lugs of another panel can fit. Two types of cartons are provided with differently located lugs, holes on the latching flap and reinforcing ribs so that the cartons can be stacked to occupy a smaller volume.

Waited ewes Alroy 154] EGG CARTON [75] Inventor: John D. Alroy, UnionCity, NJ. [73] Assignee: Borden Inc., New York, NY.

[22] Filed: Dec. 7, 1970 21 Appl. No; 95,427

[451 Jan. 23, 1973 Primary Examiner-Donald F. Norton AttorneyGeorge P.Maskas, Edward L. Mandel] and George A. Kap

[57] ABSTRACT An egg carton having a latching arrangement which includesinwardly projecting lugs on a front panel of the carton top cover whichextend into corresponding holes on a latching flap attached to thecarton tray. Reinforcing ribs extend across the carton top joining itsfront and rear panels to prevent spreading of the front panel.Depressions also are formed in the front panel of the carton top intowhich corresponding stacking lugs of another panel can fit. Two types ofcartons are provided with differently located lugs, holes on thelatching flap and reinforcing ribs so that the cartons can be stacked tooccupy a smaller volume.

11 Claims, 6 Drawing Figures Pmmgnmea ms 3,712,532

sum 1 or 2 W mvwron. JOHN D. ALROY ATTORNEYS PAIENTEnmzs ms SHEEI 2 [IF2 INVENTOR. JOHN D. ALROY 21 eMuL ATTORNEYS EGG CARTON This inventionrelates to egg carton constructions and more particularly to a novel eggcarton which has an improved latching and sealing arrangement ascompared with prior art egg cartons and which also can be stacked priorto filling in open condition occupying considerably less volume thanwould be occupied by prior art egg cartons.

Egg cartons of the molded pulp or foamed plastic material are well-knownin the art. Typical of such egg cartons are those disclosed in ReifersU.S. Pat. No. 2,888,183. These cartons include a tray having a number ofcells for holding a like number of eggs, a non-cellular cover hinged tothe backside of the tray so that it may be swung to a closed positionoverlying the tray, and a latching flap attached to the front panel ofthe tray portion. A latching arrangement is formed by cooperatingmembers on the latching flap and the front wall of the cover memberwhich include one or more projections on the latching flap andcorresponding openings in the cover front panel.

In a carton such as the type disclosed in the aforesaid Reifers U.S.Pat. No. 2,888,183 there is a substantial unsupported central area ofthe top wall of the noncellular cover member which has a tendency towarp during manufacturing. This unsupported central area also proved tobe unsatisfactory when a number of loaded cartons were stacked one ontop of another since when it is subjected to a load condition, the coverbows. This causes disengagement of the latching members on the coverfront panel and the latching flap.

An effort to correct the aforesaid deficiencies is shown in U.S. Pat.No. 3,184,133 to J. W. Boyd et al. In that patent, a hollow partitioningrib is formed on the top surface of the cover which depends from anddivides the top surface into two sections. The rib rigidly interconnectsthe front and back walls, or panels, of the cover to prevent some of theaforesaid disadvantageous effects from occurring. In addition, severaltransverse gussets are provided to connect the walls of the rib toprevent any tendency of the cover to bend or flex along the rib slongitudinal axis. The same type of latching arrangement used in theReifers patent is also used by Boyd.

' The carton of the Boyd patent also suffers from several disadvantages.First of all, the latching arrangement utilizes members which protrudefrom the latching flap through holes in the cover front panel.Therefore, a possibility exists that the latching flap can be disengagedaccidentally by pushing in on the protruding members extending throughthe front panel.

Further, the construction of this carton is such that it flap attachedto the front thereof. A cover is hinged to the rear edge of the cellulartray. A plurality of reinforcing ribs extend across the top wall of thecover connecting the front and rear panels. In accordance with oneaspect of the invention, the ribs are in the shape of a modified boxbeam which are simple to form and provide substantial rigidity. Further,the latching flap is formed with a number of holes and a correspondingnumber of inwardly extending lugs or posts are formed on the inner faceof the cover front panel. To securely close the carton it is onlynecessary to move the cover down over the latching flap until the lugson the cover extend into the holes on the latching flap. The latchingflap has a natural tendency to move outwardly, toward the cover frontpanel. The reinforcing ribs aid in providing a firm latch since thecover front panel is prevented from spreading outwardly. Thus, a secureengagement is produced between the posts on the cover front panel andthe apertures in the latching flap.

In addition to the aforesaid latching arrangement, the subject inventionalso incorporates a unique stacking feature which decreases the stackingdensity of the cartons, which would otherwise be relatively large due tothe presence of the latching lugs. In accordance with the invention, twodifferent types of cartons are provided to facilitate stacking whenempty with the covers open. Both types of cartons utilize the latchingarrangement previously described. However, as between the two cartontypes, each has a different number of lugs and holes and the location ofthese elements are different. For example, in a first type of cartonthere are two lugs and two holes while in the second type of cartonthere are three lugs and three holes. In the first carton type, havingtwo lugs and two holes, the cover front panel is formed with threestacking depressions at positions corresponding to the three lugs on thecover of the second carton type so that the three lugs of the secondtype of carton can fit within the depressions. In a similar manner, thecover front panel of the second carton type is formed with twodepressions into which the two lugs of the first carton type can belocated. Thus, the cartons can be stacked with a relatively low density.

It is therefore an object of the present invention to provide a novelegg carton with a latching arrangement wherein inwardly extending lugson the front panel, of the top cover protrude into holes of a latchingflap.

Another object is to provide an egg carton which can be stacked, inwhich the latching lugs of one type of carton fit within matingdepressions in a second type of carton.

A further object is to provide an egg carton utilizing a latchingarrangement with inwardly extending lugs on the front panel of a coverprojecting into holes in a latching flap, the cover also being providedwith a strengthening rib extending between the front and rear panels toprevent the front panel from spreading.

An additional object is to provide an egg carton with reinforcing ribsin the cover having the shape of modified box beams connecting the frontand rear panels of the cover to strengthen the cover top panel.

Other objects and advantages of the present invention will become moreapparent upon reference to the following specification and annexeddrawings, in which:

FIG. 1 is an isometric view of a first type of egg carton made inaccordance with the subject invention in an open condition;

FIG. 2 is a view similar to FIG. 1, of a second type of egg carton;

FIG. 3 is a perspective view showing the egg carton of FIG. 2 closed;

FIG. 4 is a first end view in section along the plane shown by lines 4-4of FIGS. 1 and 2 showing the stacking of the cartons;

FIG. 5 is a second, fragmentary, end view in section showing thestacking of the cartons along the cross-sectional plane of lines 5-5 ofFIGS. 1 and 2; and

FIG. 6 is a front perspective fragmentary view of a portion of anotherform of latching flap.

Two types of egg cartons, respectively designated I and II, are shown inFIGS. 1 and 2. Except for the placement of the reinforcing ribs,latching lugs and corresponding holes on the latching flap, theconstruction of the two egg carton types are identical. Therefore, theyare both described simultaneously with the suffix reference numeral -1given to the differently located elements of carton type I and suffixreference numeral 2 given to the elements of carton type II. Each of thecarton types is formed of the same material and by the same process. Forexample, they can be made of pulp, cardboard or plastic by any suitableprocess, such as molding.

Each carton has a lower tray 10 formed with a number of individual,generally concave cells 12, there being one cell 12 for each egg. Thebottom of each cell is shown as being flat. In the most commonconfiguration, which is shown in the drawings, there are two rows of sixcells 12 to hold a dozen eggs. Of course, other cell arrays, such asthree by four, can be used. A quad of adjacent cells are joined by agenerally convex projection 13 which are the terminal points of celldivider walls 14. The projections 13 are hollow on the bottom side ofthe tray so that another projection 13 can fit within the hollow portionwhen the cartons are stacked. Walls 14 extend both parallel andtransversely to the longitudinal axis of the tray 10. The projections 13extend above the cell walls and also above a peripheral rim 16 which isformed around all four sides of the tray. Extending upwardly from thefront of the peripheral rim 16 is a latching flap 20. The latching flap20 is bent upwardly from rim 16 so that it has a natural tendency tomove outwardly with respect to the central cell area of tray 10.

A cover 30 is hinged at 32 to the rear portion of the tray rim 16. Thehinge can be of any suitable, conventional construction. The cover 30has respective front, rear and side panels 30a, 30b and 300 whichsurround and depend downwardly from a top wall 30d. The panels 30a, 30band 300 taper outwardly slightly from top panel 30d so that the coversof the carton also can be stacked. A partial peripheral lip 33 is formedaround the front and the two side panels 300 and 30c.

A plurality of reinforcing ribs 35 are formed in the top wall 30d andextend between the cover front and back panels 30a and 30b. The ribs 35depend downwardly from the top panel 30d and are shown as being ofgenerally rectangular shape with two parallel side walls and a joiningbottom wall. This forms a threesided box-beam. As seen in FIG. 3, theribs 35 are depressed areas of the cover top panel 30d which are formedduring the molding operation. It has been found that the box-beamconstruction provides substantial rigidity between the front and rearpanels 30a and 30b. It is preferred that the ribs 35 each have a depthof from about one-quarter to about one-third the total height of thecover to provide the desired structural rigidity between the front andrear panels.

A plurality of inwardly projecting latching lugs 40 are formed on thefront panel 30a. It is preferred that at least two such lugs 40 beprovided to assure adequate latching. Two lugs 40-1 are shown for cartontype I of FIG. 1, while carton type II of FIG. 2 has three lugs 40-2. Itis preferred that the lugs 40 be angled upwardly slightly, with theinner end of each lug being pointed toward the cover top 30d. Thisprovides a better latching action as is described below.

A plurality of lug-stacking depressions 45 are also formed on the frontpanel 30a of each carton. The size and shape of each lug-stackingdepression 45 is such that a lug 40 can fit therein. The bottom of eachlug 40 is closer to the tray peripheral edge 33 than the bottom of adepression. This permits stacking, as is described below. Thedepressions are shown as being generally rectangular in shape and havingtheir walls extending inwardly toward the interior of the cover. Anysuitable shape can be used.

As shown in FIGS. 1 and 2, each stacking lug depression 45 has itscenter on a plane which passes through the longitudinal axis of a rib 35and lies parallel to the side walls forming the rib. If desired, theportion of the rib 35 which terminates at the front panel 30a can beextended downwardly toward the cover peripheral edge 33 so that thetermination of a rib 35 at the front panel 30a will join with the wallsdefining the corresponding depression 45. Alternatively, the rib can bemade deeper to obtain the latter structure.

Carton type I has three lug stacking depressions 45-1 on the front panel30a located at points corresponding to the three latching lugs 40-2 on acarton type II. In a similar manner, carton type II has two stacking-lugdepressions 45-2 on its front panel 30a, located at points correspondingto the two latching lugs 40-1 of a type I carton.

The latching flap 20 has a height above the tray rim 16 which ispreferably slightly less than that of the cover front panel 30a. Aplurality of circular openings 50 are formed in the latching flap atpositions which are in line with the latching lugs 40 on the samecartons front panel 30a. Each opening 50 has a diameter sufficientlylarge to accept a lug 40. The latching flap is also formed with a numberof cutouts 52 of a shape corresponding generally to the shape of thetermination of the cartons reinforcing ribs 45 at the front panel 30.Each cutout 52 is in line with a respective rib 45.

The latching flap 20 is preferably formed in a generally serpentineshape, viewed from the top, with outwardly extending portions 20a andinwardly extending portions 20b. The apertures 50 and the cutouts 52 areformed in the inwardly extending portions 20b of the flap. The inwardlyextending portions 20b are in line with the projections on the frontpanel formed by the projections 45 so that these projections will not beable to push the latching flap inwardly too far, if at all. It should beunderstood, of course, that a straight flap 20 can be employed insteadof the serpentine shape shown.

As is seen by comparing FIGS. 1 and 2, the latching flaps of cartontypes I and II differ somewhat. A type I carton has cutouts 52-1 on thetwo end and center outwardly extending flap portions 20b and openings50-1 on the two intermediate portions b. This pattern of openings andcutouts is reversed on the flap of a type II carton.

To seal the carton after it has been filled with eggs, the latching flap20 is bent up to the position shown, if it is not already in thatposition. The cover is plowed down until the latching lugs lock into thecorresponding openings 50 in the latching flap. The latching flap has aninherent tendency to move outwardly. However, this is resisted by theflap engaging cover front panel 300. The reinforcing ribs prevent anoutward spreading of the front panel 30a so that the latch is keptsecure. Due to the upward angle of lugs 40, a wedging action is producedbetween a lug and 15 the portion of the flap surrounding thecorresponding opening 50, when there is an upward force on an alreadysealed cover. To open the cover both an upward and an outward force mustbe applied to cover front panel 30a.

It should be noted that the locking lugs 40 extend inwardly from panel300 and are not exposed as in the carton of the aforesaid Reiferspatent. Therefore, there is little or no likelihood of the cover beingaccidentally disengaged from the apertures 50 by someone pushinginwardly on the latching lugs, as could occur in the Reifers structure.

FIGS. 4 and 5 show the stacking of the types I and II cartons which aredesignated accordingly. A type II carton of FIG. 2 is the lowest cartonin the stack, with a type Icarton of FIG. 1 nested on top of it, and asecond type II carton nested on top of the type I carton. Crosssectionsare shown at two different positions of the two carton types in thestack. While only three cartons are shown, since this demonstrates theprinciples of the invention, it should be understood that a greaternumber of cartons can be stacked one within the other. Since the trays10 of both types of cartons are identical, they stack with theprojections 13 nesting inside of each other. The latching flap 20 ofeach carton fits within the flap of the next lower carton of the stack.

The bottom carton in the stack is a type II carton and the sectionstaken along lines 4-4 of FIGS. 1 and 2,

shows a stacking lug40-2 of this carton nesting within a depression -1of the middle type I carton. Similarly, in FIG. 5, the latching lug 40-1of the middle type I carton is shown nested in the stacking depression45-2 of the top type II carton. As should be apparent, the threelatching lugs 40-2 of the lowest type II carton fit within the threedepressions 45-1 of the middle type I carton while the two lugs 40-1 ofthe middle type I carton fit within the two depressions 45-2 of the toptype II carton. This nesting sequence of parts 40 and 45 is repeated foradditional cartons added to the stack.

The use of the two different carton types and their respectivelydifferently located latching lugs and lug depressions, which arecomplementary to each other, increases the stacking density of thecartons. It would take a considerably greater volume to stack the samenumber of cartons if the stacking arrangement of the subject inventionwas not utilized. This should be apparent when it is considered that thecover of each carton would be able to nest into the cover of the nextlower carton only to a point where the front panel of the cover of theupper carton would be stopped by the inwardly projecting latching lugson the cover of the next lower carton. By utilizing the subjectinvention the cover of the upper carton can move down further into thenext lower carton on the stack since the latching lugs of the latter nowfit into the depressions of the former thereby permitting furtherdownward movement of the upper carton than could previously be obtained.

As shown in FIGS. l and 2, each rib 35 and its corresponding flap cutout52 lies in line with the center of a respective projection 13 in bothcarton types. This particular location for these elements are notcritical. They are desirable, however, from the point of view that theheight of a projection 13 and/or the height of a rib 35 in line with itcan be made so that they engage one another when the cover is closed.This increases the load bearing capacity of the cover since it issupported at the additional points of its top panel 30d where the ribs35 engage the projections 13.

FIG. 6 shows a portion of a modified form of latching flap. Here, thestep portions 20a and 20b of the flap are reversed so that portions 20blie closer to the front panel of the cover when it is closed. Thisprovides better latching action since portions 20b will lie closer tothe cover front panel when it is closed. Each cutout 72 on a flapportion 20b which lies in line with a rib 35 and a depression 45 isformed with two parts 72a and 72b. The upper part 72a starts at theupper edge of the flap and is shaped to accept a portion of acorresponding reinforcing rib 35 as in FIGS. 1-5. The lower part 72b isshaped to accept an inward projection on the front panel 30a of a cartontop which forms the depression 45. Thus, the outwardly extendingportions'20b of the flap will all lie close to the cover front panelwhen it is closed since the projections of depressions 45 will fit intocutout part 72b and cannot push the flap 20 inwardly. While the twoparts of the cutout are shown joined together, it should be understoodthat they can be separated.

What is claimed is:

1. In a carton comprising a cellular tray, a latching flap attached toand extending upwardly from the front of the tray, said latching flapformed with a plurality of openings, a cover hingedly attached to therear of said tray, said cover having a front, rear and side panels whichdepend from the cover top, a plurality of inwardly projecting latchinglugs of a number equal to the number of openings on the latching flapformed on the front panel of said cover at locations corresponding tosaid openings, said latching lugs extending into said openings when thecover is moved over the latching flap to engage the portions of thelatching flap surrounding the openings to hold the cover to the flap;

the improvement wherein said front panel is also formed with at leastone inwardly extending projection which defines a depression on theoutside of the front panel projection at a position to accept aninwardly extending latching lug on the cover of the front panel ofanother carton stacked in an open condition below the carton whose frontpanel has said depression.

2. The improvement of claim 1 wherein a plurality of reinforcing ribsare formed in the top panel of said cover joining the front and rear.panels thereof.

3. The improvement of claim 2 wherein said latching flap is also formedwith at least one cutout at the upper edge of the panel into which aportion of the rib fits when the cover is closed over said latchingflap, and

another cutout into which said projection forming the depression fitswhen the cover is closed over said latching flap.

4. The improvement of claim 3 wherein one of said ribs and a saidprojection forming a depression lie along the same line, said cutoutsbeing formed as one continuous cutout having one portion to accept thesaid portion of the rib and another portion to accept said projectionwhen the cover is closed over said latching flap.

5. In a carton comprising a cellular tray, a latching flap attached toand extending upwardly from the front of the tray, said latching flapformed with a plurality of openings, a cover hingedly attached to therear of said tray, said cover having a front, rear and side panels whichdepend from the cover top, a plurality of inwardly projecting latchinglugs of a number equal to the number of openings on the latching flapformed on the front panel of said cover at locations corresponding tosaid openings, said latching lugs extending into said openings when thecover is moved over the latching flap to engage the portions of thelatching flap surrounding the openings to hold the cover to the flap;

the improvement wherein said front panel is also formed with a pluralityof extending inwardly projections each of which defines a depression onthe outside of the front panel, each of said depressions being locatedat a position to accept an inwardly extending latching lug on the coverof the front panel of another carton stacked in an open conditionbeneath the carton whose front panel has said depressions.

6. The improvement of claim 5 wherein said projections forming saiddepressions on the front panel of the cover are offset from the inwardlyextending latching lugs on said front panel.

7. The improvement of claim 6 wherein there are a different number ofprojections and latching lugs on the front panel of the cover.

8. The improvement of claim 5 and further comprising in combinationtherewith a second carton having the same tray construction as thefirst-named carton so that the trays of said two cartons can nest onewithin the other, said second carton also having a latching flapextending upwardly from the front of the tray, a cover hingedly attachedto the rear of the tray, said cover having a front, rear and side panelswhich depend from the cover top, a plurality of inwardly extendinglatching lugs formed on the front panel of said cover equal in number tothe depressions on the front panel of said first-named carton andlocated to fit therein when said second carton is stacked below saidfirst carton, and a plurality of inwardly extending projections on thefront panel of said second carton each of which forms a depression, saidprojections located on the front panel of said second carton so that thelatching lugs on the front panel of the first-named carton can fittherein when the said first-named carton is stacked below said secondcarton.

9. The improvement of claim 8 wherein said firstnamed carton has an oddnumber of latching lugs and an even number of projections forming saiddepresionsand said second carton has an even number of atching lugs andan odd number of pro ections forming the depressions.

10. The improvement of claim 9 wherein each said carton has a respectivereinforcing rib extending between the front and rear panels of the coverand lying in line with each said projection forming a depression.

11. The improvement of claim 10 wherein each said latching flap isformed with a cutout within which a portion of a reinforcing rib fitswhen the cover is closed.

1. In a carton comprising a cellular tray, a latching flap attached toand extending upwardly from the front of the tray, said latching flapformed with a plurality of openings, a cover hingedly attached to therear of said tray, said cover having a front, rear and side panels whichdepend from the cover top, a plurality of inwardly projecting latchinglugs of a number equal to the number of openings on the latching flapformed on the front panel of said cover at locations corresponding tosaid openings, said latching lugs extending into said openings when thecover is moved over the latching flap to engage the portions of thelatching flap surrounding the openings to hold the cover to the flap;the improvement wherein said front panel is also formed with at leastone inwardly extending projection which defines a depression on theoutside of the front panel projection at a position to accept aninwardly extending latching lug on the cover of the front panel ofanother carton stacked in an open condition below the carton whose frontpanel has said depression.
 2. The improvement of claim 1 wherein aplurality of reinforcing ribs are formed in the top panel of said coverjoining the front and rear panels thereof.
 3. The improvement of claim 2wherein said latching flap is also formed with at least one cutout atthe upper edge of the panel into which a portion of the rib fits whenthe cover is closed over said latching flap, and another cutout intowhich said projection forming the depression fits when the cover isclosed over said latching flap.
 4. The improvement of claim 3 whereinone of said ribs and a said projection forming a depression lie alongthe same line, said cutouts being formed as one continuous cutout havingone portion to accept the said portion of the rib and another portion toaccept said projection when the cover is closed over said latching flap.5. In a carton comprising a cellular tray, a latching flap attached toand extending upwardly from the front of the tray, said latching flapformed with a plurality of openings, a cover hingedly attached to therear of said tray, said cover having a front, rear and side panels whichdepend from the cover top, a plurality of inwardly projecting latchinglugs of a number equal to the number of openings on the latching flapformed on the front panel of said cover at locations corresponding tosaid openings, said latching lugs extending into said openings when thecover is moved over the latching flap to engage the portions of thelatching flap surrounding the openings to hold the cover to the flap;the improvement wherein said front panel is also formed with a pluralityof extending inwardly projections each of which defines a depression onthe outside of the front panel, each of said depressions being locatedat a position to accept an inwardly extending latching lug on the coverof the front panel of another carton stacked in an open conditionbeneath the carton whose front panel has said depressions.
 6. Theimprovement of claim 5 wherein said projections forming said depressionson the front panel of the cover are offset from the inwardly extendinglatching lugs on sAid front panel.
 7. The improvement of claim 6 whereinthere are a different number of projections and latching lugs on thefront panel of the cover.
 8. The improvement of claim 5 and furthercomprising in combination therewith a second carton having the same trayconstruction as the first-named carton so that the trays of said twocartons can nest one within the other, said second carton also having alatching flap extending upwardly from the front of the tray, a coverhingedly attached to the rear of the tray, said cover having a front,rear and side panels which depend from the cover top, a plurality ofinwardly extending latching lugs formed on the front panel of said coverequal in number to the depressions on the front panel of saidfirst-named carton and located to fit therein when said second carton isstacked below said first carton, and a plurality of inwardly extendingprojections on the front panel of said second carton each of which formsa depression, said projections located on the front panel of said secondcarton so that the latching lugs on the front panel of the first-namedcarton can fit therein when the said first-named carton is stacked belowsaid second carton.
 9. The improvement of claim 8 wherein saidfirst-named carton has an odd number of latching lugs and an even numberof projections forming said depressions and said second carton has aneven number of latching lugs and an odd number of projections formingthe depressions.
 10. The improvement of claim 9 wherein each said cartonhas a respective reinforcing rib extending between the front and rearpanels of the cover and lying in line with each said projection forminga depression.
 11. The improvement of claim 10 wherein each said latchingflap is formed with a cutout within which a portion of a reinforcing ribfits when the cover is closed.